U.S. patent application number 10/431696 was filed with the patent office on 2004-09-23 for interior vehicle trim panel.
Invention is credited to Adams, Robert J., Cowelchuk, Glenn A., DePue, Todd, Hier, Michael J..
Application Number | 20040183279 10/431696 |
Document ID | / |
Family ID | 32988306 |
Filed Date | 2004-09-23 |
United States Patent
Application |
20040183279 |
Kind Code |
A1 |
DePue, Todd ; et
al. |
September 23, 2004 |
Interior vehicle trim panel
Abstract
An overmolded interior vehicle trim panel includes a substrate
having a front face and an under face. The under face has a tear
seam integrally molded therein to allow an airbag to exit the
substrate when the airbag is deployed. The tear seam defines an
airbag door. An outer layer is bonded to the front face of the
substrate in a mold, thereby forming an overmolded interior vehicle
trim panel. The trim panel can include a sheet of hinge material
attached to one of the substrate and the outer layer of the
overmolded interior trim panel. A portion of the sheet of hinge
material defines a hinge member.
Inventors: |
DePue, Todd; (Brighton,
MI) ; Adams, Robert J.; (Ypsilanti, MI) ;
Hier, Michael J.; (Milford, MI) ; Cowelchuk, Glenn
A.; (Chesterfield Township, MI) |
Correspondence
Address: |
MACMILLAN, SOBANSKI & TODD, LLC
ONE MARITIME PLAZA-FOURTH FLOOR
720 WATER STREET
TOLEDO
OH
43604
US
|
Family ID: |
32988306 |
Appl. No.: |
10/431696 |
Filed: |
May 8, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10431696 |
May 8, 2003 |
|
|
|
10394130 |
Mar 21, 2003 |
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Current U.S.
Class: |
280/728.3 |
Current CPC
Class: |
B29C 45/1676 20130101;
B29L 2031/3055 20130101; Y10T 428/15 20150115; B29L 2031/3038
20130101; B29L 2031/3008 20130101 |
Class at
Publication: |
280/728.3 |
International
Class: |
B60R 021/20 |
Claims
What is claimed is:
1. An overmolded interior vehicle trim panel comprising: a
substrate having a front face and an under face, said under face
having a tear seam integrally molded therein to allow an airbag to
exit said substrate when said airbag is deployed, said tear seam
defining an airbag door; and an outer layer bonded to said front
face of said substrate in a mold, thereby forming an overmolded
interior vehicle trim panel.
2. The trim panel according to claim 1, further including a sheet
of hinge material attached to one of said substrate and said outer
layer of said overmolded interior trim panel, a portion of said
sheet of hinge material defining a hinge member.
3. The trim panel according to claim 1, wherein said tear seam is
integrally formed in said substrate.
4. The trim panel according to claim 3, wherein said tear seam is
defined by a plurality of cavities integrally formed in said
substrate.
5. The trim panel according to claim 1, wherein said outer layer is
mechanically bonded to said substrate.
6. The trim panel according to claim 1, wherein said outer layer is
sprayed on to said front face of said substrate.
7. The trim panel according to claim 1, wherein said sheet of hinge
material is integral with said substrate.
8. The trim panel according to claim 1, wherein said sheet of hinge
material is integral with said outer layer.
9. The trim panel according to claim 1, wherein a portion of said
sheet of hinge material covers said tear seam.
10. The trim panel according to claim 1, wherein said sheet of
hinge material includes a scrim integrally formed therein.
11. The trim panel according to claim 10, wherein said sheet of
hinge material and said scrim are formed by extrusion.
12. The trim panel according to claim 10, wherein said scrim is
embedded within said sheet of hinge material.
13. The trim panel according to claim 10, wherein said scrim is
attached to an outer surface of said sheet of hinge material.
14. The trim panel according to claim 1, wherein when said airbag
is deployed, said airbag door remains attached to said substrate at
said hinge member.
15. The trim panel according to claim 1, wherein said outer layer
includes a front face and an under face, wherein said hinge portion
has a first end and a second end, and wherein a portion of said
tear seam extends through said substrate to said under face of said
outer layer, said portion of said tear seam in said outer layer
extending between said first and said second ends of said hinge
portion.
16. The trim panel according to claim 1, wherein said tear seam is
substantially U-shaped, an open end of said U-shaped tear seam
defining said hinge member.
17. The trim panel according to claim 1, wherein said trim panel is
instrument panel.
18. The trim panel according to claim 1, wherein said tear seam is
formed by a laser.
19. The trim panel according to claim 1, wherein when said airbag
is deployed, said hinge portion of said outer layer remains
attached to said substrate.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S.
application Ser. No. 10/394,130 filed Mar. 21, 2003.
TECHNICAL FIELD
[0002] This invention relates to interior vehicle trim panels. More
particularly, the invention relates to an improved seamless airbag
door in an interior vehicle trim panel.
BACKGROUND OF THE INVENTION
[0003] Incorporation of airbags into vehicles has created many
design challenges for automotive designers. It is desirable to
incorporate an airbag into an instrument panel in front of the
vehicle passenger seat. When incorporating an airbag into an
instrument panel it is necessary to provide the airbag cover
portion in the instrument panel that will reliably and safely tear,
such that the passenger is protected. To this end, a tear seam has
generally been provided in the airbag cover portion of an
instrument panel to insure that the airbag will safely deploy.
[0004] Vehicle designers prefer to have a continuous surface on the
front face of the instrument panel whenever possible, so they would
prefer to avoid having a tear seam in the instrument panel. Thus,
recently there has been an effort to achieve a "seamless" design
wherein there is no indication on the front face of the instrument
panel that the airbag is behind the instrument panel. To achieve
this design, tear seams or tear strips provided in the instrument
panel are only provided on the under face, and not on the front
face of the instrument panel.
[0005] While it is also desirable that the instrument panel be
relatively stiff so as to properly secure an air bag support
assembly thereto, it is also desirable that the surface of the
surface of the instrument panel which faces the occupants of a
vehicle be soft and smooth to the touch.
[0006] The instrument panel must perform the utilitarian function
of breaking apart along its tear seam to allow the air bag to exit
through the airbag portion of the instrument panel when deployed.
The airbag cover portion of an instrument panel is often complex
and difficult to assemble. Accordingly, it is desirable to provide
an improved instrument panel. Preferably, such an improved
instrument panel would be soft and smooth to the touch, be less
complex, and be easier to assemble than known instrument
panels.
SUMMARY OF THE INVENTION
[0007] This invention relates to an overmolded interior vehicle
trim panel. The trim panel includes a substrate having a front face
and an under face. The under face has a tear seam integrally molded
therein to allow an airbag to exit the substrate when the airbag is
deployed. The tear seam defines an airbag door. An outer layer is
bonded to the front face of the substrate in a mold, thereby
forming an overmolded interior vehicle trim panel.
[0008] An alternate embodiment of the trim panel includes a sheet
of hinge material attached to one of the substrate and the outer
layer of the overmolded interior trim panel. A portion of the sheet
of hinge material defines a hinge member.
[0009] Various objects and advantages of this invention will become
apparent to those skilled in the art from the following detailed
description of the preferred embodiment, when read in light of the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a partial perspective view of an instrument panel
manufactured according to the invention.
[0011] FIG. 2 is a cross-sectional view of a portion of the
instrument panel taken along line 2-2 of FIG. 1, showing the airbag
door.
[0012] FIG. 3 is a cross-sectional view of a first mold assembly
for manufacturing the instrument panel illustrated in FIG. 1.
[0013] FIG. 4 is a cross-sectional view of a second mold assembly
for manufacturing the instrument panel illustrated in FIG. 1.
[0014] FIG. 5 is a bottom plan view of the instrument panel
illustrated in FIG. 1, showing the tear seam and the sheet of hinge
material.
[0015] FIG. 6 is an enlarged bottom plan view of a portion of the
instrument panel illustrated in FIG. 5, showing the cavities
defining the tear seam.
[0016] FIG. 7 is a bottom plan view of an alternate embodiment an
instrument panel manufactured according to the invention, showing
an alternate embodiment of the tear seam.
DETAILED DESCRIPTION OF THE INVENTION
[0017] Referring now to the drawings, there is illustrated in FIG.
1, an instrument panel, indicated generally at 10. The instrument
panel 10 is an example of a trim panel for mounting in an interior
cabin of a vehicle. It will be appreciated however, that the trim
panel 10 of the subject invention may be any type of trim panel
associated with a vehicle. Other suitable examples of trim panels
include door panels, center consoles, overhead consoles, and other
various interior panels for covering the sides, ceilings, and/or
vertical pillars of the frame members of the vehicle.
[0018] The instrument panel 10 is installed on a vehicle frame
generally in the area underneath the windshield and between the
engine compartment and the interior of the vehicle. The instrument
panel 10 can include any suitable frame structure (not shown) for
supporting the instrument panel 10 to the vehicle frame. The
portion of the exemplary instrument panel 10 illustrated in FIG. 1
includes a show, or front face 14 and a glove box 16. Since the
front face 14 of the instrument panel 10 are within reach and
direct sight of the occupants of the vehicle, it is desirable for
this portion of the instrument panel 10 to be aesthetically
pleasing in color and texture, as well as having a desirable
tactile feel, such as a soft of slightly elastic feel.
[0019] Shown in phantom outline in FIG. 1 is an airbag support
assembly 18 and a tear seam 20 located behind the front face 14 of
the instrument panel 10. Preferably, the tear seam 20 defines an
airbag door 22. It will be appreciated that the tear seam 20 can be
any weakened area of the instrument panel 10, such that an airbag
23, as shown in phantom outline in FIG. 2 can exit the instrument
panel 10 when the airbag 23 is deployed, for example, during a
vehicle collision. As shown in FIGS. 1 and 5, the tear seam 20 has
a substantially rectangular shape. However, it will be appreciated
that the tear seam 20 can be of any desired shape, such as a
U-shaped tear seam 24, as shown in FIG. 7, or an H-shaped tear seam
(not shown). The tear seam 20 can be formed by any desired method,
such as by laser scoring. Preferably, the tear seam 20 is defined
by a plurality of cavities 25 integrally formed in the instrument
panel 10, as best shown in FIG. 6.
[0020] As shown in FIG. 2, the instrument panel 10 generally
includes a substrate 26 and an outer layer 32. The substrate
includes a front face 28 and an under face 30. The outer layer 32
generally covers the front face 28 of the substrate 26. The exposed
surfaces of the substrate 26 are generally represented with
stippling in FIG. 1. As will be discussed below in more detail
below, an exposed portion 33 of the substrate 26 may be uncovered
from the outer layer 32 to provide a two tone or dual material
appearance. Portions of the substrate 26 may be exposed and
viewable by passengers of the vehicle. The substrate 26 and the
outer layer 32 can have any suitable contour and apertures for
receiving various vehicle controls, components, and systems.
[0021] The substrate 26 is preferably made of a relatively rigid
material. Preferably, the instrument panel 10 is made of a polymer
or plastic material. Examples of suitable materials for the
instrument panel 10 include thermoplastic elastomer, thermoplastic
elastomer polyolefin, polycarbonate, polypropylene, ABS
(acrylonitrile butadiene styrene), polycarbonate ABS, SMA (styrene
maleic anhydride), polyphenylene oxide (PPO), nylon, polyester,
acrylic, and polysulfone. More preferably, the substrate 26 is
formed of a molded plastic material, such as thermoplastic olefin
(TPO). However, it will be appreciated that the substrate 26 can be
formed of any other desired material. The substrate 26 can also
have any suitable textured surface and color. The tear seam 20 is
formed in the under face 30 of the substrate 26.
[0022] An outer layer 32 is bonded to the front face 28 of the
substrate 26. The outer layer 32 is preferably made of a softer
material than the substrate 26 and has a generally soft tactile
feel compared to the substrate 26. Preferably, the outer layer 32
is made of a polymer or synthetic rubber. Examples of suitable
materials for the outer layer 32 include thermoplastic elastomer,
thermoplastic elastomer polyolefin. The outer layer 32 can also
have any suitable textured surface and color. Preferably, the outer
layer 32 is of a different material than the substrate 26 so that
the surface of the outer layer 32 has a different tactile
characteristic than the surface of the substrate 26. For example,
the substrate 26 can have a lower coefficient of friction than the
outer layer 32. More preferably, the outer layer 32 is formed of
thermoplastic elastomer (TPE) that forms an outer decorative
surface of the instrument panel 10.
[0023] The outer layer 32 can be bonded to the substrate 26 by any
desired method. Preferably, the outer layer 32 is mechanically
bonded to the substrate 26 in a mold. More preferably, the outer
layer 32 is mechanically bonded to the substrate 26 in a two-shot
injection mold, thereby defining an overmolded instrument panel 10.
It will be appreciated that the outer layer 32 can be bonded to the
substrate 26 by any other desired method, such as by spraying the
outer layer 32 onto the front face 28 of the substrate 26.
[0024] It will be appreciated that various covers and panels (not
shown) may be also be attached to the substrate 26 or the outer
layer 32 to cover selected positions thereof. For example, an
aesthetically pleasing trim panel, such as a faux wood or carbon
fiber panel (not shown) may be used to cover a portion of the
substrate 26. Other components, such as vent covers, display
devices, electronic controls, audio/video entertainment units, and
the like may be attached to the substrate 26 of the instrument
panel 10.
[0025] In the exemplary embodiment illustrated in FIG. 2, a sheet
of a sheet of hinge material 34 is attached between the substrate
26 and the outer layer 32. Preferably, the hinge material 34 is
attached to the airbag door 22 during a molding process, such as
insert molding, compression molding, two-shot molding, and the
like. However, the hinge material 34 can be attached to the airbag
door 22 by any other desired method. A portion of the hinge
material 34 defines a hinge member 38 having a first end 40 and a
second end 42, as shown in FIGS. 5 and 7. It will be appreciated
that, if desired, the hinge material 34 can be embedded within the
substrate 26, embedded within the outer layer 32, or bonded to an
under face 43 of the airbag door 22.
[0026] Preferably, the hinge material 34 is attached to
substantially the entire airbag door 22, such that the hinge
material 34 substantially covers all of the under face 30 within
the tear seam 20, as shown in FIG. 5. It will be understood that
"substantially all of the under face" is defined herein as within
the range of from about 80 percent to about 100 percent of the
under face 30 within the tear seam 20. The sheet of hinge material
34 is preferably formed of a relatively flexible material. More
preferably, the hinge material 34 is formed of thermoplastic
elastomer (TPE). It will be appreciated however, that the hinge
material 34 can be any desired material, such as steel.
[0027] The sheet of hinge material 34 preferably includes a scrim
44 attached thereto. Such a scrim 44 provides increased tensile
strength to the sheet of hinge material 34. Preferably, the scrim
44 is embedded within the sheet of hinge material 34 by any desired
method, such as insert molding, compression molding, two-shot
molding, and the like. More preferably, the scrim 44 is embedded
within the sheet of hinge material 34 during an extrusion process,
as is known to one skilled in the art. The scrim 44 can be formed
from any desired material, such as polyester or nylon.
[0028] The instrument panel 10 or other vehicle components are
preferably manufactured by a generally two step mold process, as
schematically illustrated in FIGS. 3 and 4 with respect to the
cross sectional view of FIG. 2. As shown in FIG. 3, a first mold
structure 46 is movably mounted relative to a second mold structure
48. The mold structures 46 and 48 include contour surfaces 50 and
52, respectively, facing one another in a spaced apart relationship
which define a cavity 54. The cavity 54 generally corresponds to
the shape and the dimension of the substrate 26 and the sheet of
hinge material 34. The first and second mold structures 46 and 48
are moved together to their position illustrated in FIG. 3, and the
sheet of hinge material 34 is disposed within the cavity 54. A
first material (as shown in section in the cavity 54) is the
introduced into the cavity 54 to form the substrate 26. The first
material is introduced into the cavity 54 in a liquefied form and
is partially or completely cooled and/or cured to form the
substrate 26. The surface 52 corresponds to the front face 28 of
the substrate 26 facing the interior of the vehicle, as shown in
FIG. 1. The surface 50 generally corresponds to the under face 30
(not viewable in FIG. 1) facing the engine compartment.
[0029] Next, the second mold structure 48 is moved from the first
mold structure 46, and a third mold structure 56 is generally
positioned in its place, as shown in FIG. 4. Preferably, the
substrate 26 and the sheet of hinge material 34 remain on the first
mold structure 46 during replacement of the second mold structure
48. The third mold structure 56 includes a contour surface 58
facing the substrate 26 and the contour surface 50 of the first
mold structure 46. The contour surface 58 of the third mold
structure 56 and a surface 60 of the sheet of hinge material 34 are
spaced apart from one another to define a cavity 62. The cavity 62
generally corresponds to the shape and dimension of the outer layer
32. A second material is then introduced into the cavity 62 to form
the outer layer 32 such that the outer layer 32 is overmolded onto
the surface 36 substrate 26.
[0030] It should be understood that the first and second materials
can be introduced into the cavities 28 and 38 at any suitable
temperature and pressure and with or without any other materials,
such as for example, a blowing agent. Alternatively, either the
substrate 26 and/or the outer layer 32 may be formed by a reaction
injection molding process mixing two different materials together,
such as a resin and a catalyst. For example, it may be preferred to
form the outer layer 32 with a liquid two component urethane
injected under low pressure without a blowing agent such that the
outer layer 32 remains a solid skin.
[0031] The second material of which the outer layer 32 is made of
may include an optional adhesive promoter to form a bond between
the surface 36 of the substrate 26 and the outer layer 32. The
first and second materials could also be heated or maintained at an
adequate temperature so that a melted bond formed therebetween.
Alternatively, a separate adhesive layer (not shown) could be
introduced between the substrate 26 and the outer layer 32 to form
a laminated instrument panel 10.
[0032] The combination substrate 26 and the outer layer 32 are then
removed from first and third mold structures 46 and 56, thereby
forming the portion of the instrument panel 10. The mold structures
can be any conventional mold structures and can be positioned and
moved by any suitable conventional means. For example, the first
mold structure 46 may remain stationary, and the second and third
mold structures 48 and 56 being moved into and out of their
respective positions relative to the first mold structure 46.
Although the first mold structure 46 is shown and described as
being stationary, it should be understood that any of the mold
structures can be moved to any position relative to one another
throughout the process to manufacture the instrument panel 10.
[0033] The instrument panel 10 may be formed such that the outer
layer 32 does not completely overmold the substrate 26, thereby
revealing the exposed portion 33. This provides an instrument panel
10 having a decorative two-tone, material appearance. As shown in
FIG. 4, the third mold structure 56 includes a portion 64 which
covers the exposed portion 33 of the substrate 26 to prevent the
second material from overmolding onto the substrate 26. Although
not necessary, it is preferred that the surfaces of the instrument
panel 10 facing the interior of the vehicle are generally flush
with one another. To accomplish this, the substrate 26 is formed
with an outwardly extending ridge 63 positioned so that its outward
surface is flush with the outward surface of the outer layer 32.
Although the exposed portion 33 of the substrate 26 is shown at
some intermediate point in the instrument panel 10 such that the
exposed portion 33 is enclosed or surrounded by the outer layer 32,
it should be understood that the exposed portion, or a plurality of
exposed portions, may be formed anywhere on the instrument panel
10, for example, on the edge thereof.
[0034] The outer layer 32 defines the front face 14 of the
instrument panel 10, and includes an under face 65. As shown in
FIG. 2, a portion of the tear seam 20 can extend through the
substrate 26 to the under face 65 of the outer layer 32. If
desired, the tear seam can also extend through a portion of the
outer layer 32, as shown by a phantom outline 20A. However, it will
be appreciated that, preferably, the tear seam 20 does not extend
into or through the hinge member 38 of the outer layer 32.
[0035] When the U-shaped tear seam 24, as shown in FIG. 7, is
provided, the tear seam 24 preferably extends between the first and
the second ends 40 and 42, respectively, of the hinge member 38,
such that an open end of the U-shaped tear seam 24 defines the
hinge member 38.
[0036] Shown in phantom outline in FIG. 2, is an airbag housing 66
and an airbag collar 68. The airbag collar 68 is attached to the
under face 30 of the substrate 26 about the tear seam 20. The
collar 68 is preferably formed of a molded plastic material, such
as TPO. However, it will be appreciated that the collar 68 can be
formed of any other desired material. The collar 68 is attached to
the substrate 26 by any desired method, such as by vibration
welding. It will be appreciated however, that the collar 68 can be
integrally formed with the substrate 26 or can be attached to the
substrate 26 by any other desired attachment method.
[0037] Preferably, the airbag housing 66 is attached to the collar
68 with threaded fasteners 70. However, threaded fasteners 70 are
not required, and the airbag housing 66 can be attached to the
collar 68 by any desired attachment means. The airbag housing 66
preferably includes an airbag inflator 72 and the airbag 23. The
airbag inflator 72 and the airbag 23 are shown schematically in
FIG. 2 for illustration purposes since they are known in the art
and their construction forms no part of the invention. As will be
understood by one of ordinary skill in the art, the shape of the
airbag housing 66, airbag inflator 72, and airbag 23 may vary from
that shown.
[0038] As best shown in FIG. 2, when the airbag 23 deploys it will
initially be forced against the under face 43 of the airbag door
22. The airbag 23 then ruptures the instrument panel 10 along the
tear seam 20 such that the airbag door 22 (the portion of the
instrument panel 10 within the outline of the tear seam 20)
separates from the rest of the instrument panel 10 and moves
outward of the instrument panel 10. The hinge member 38 of the
hinge material 34 permits the airbag door 22 to rotate outwardly so
that the airbag 23 can be released into the passenger compartment
of the vehicle. During and after deployment of the airbag 23 the
airbag door 22 remains attached to the 5 instrument panel 10 by the
hinge member 38 of the hinge material 34.
[0039] The principle and mode of operation of this invention have
been described in its preferred embodiment. However, it should be
noted that this invention may be practiced otherwise than as
specifically illustrated and described without departing from its
scope.
* * * * *